Trailer having improved side wall

ABSTRACT

A cargo trailer includes a floor and a side wall extending vertically upward from a side edge of the floor. The side wall includes a plurality of generally vertical posts. Each post defines an interior surface disposed in a generally common plane and a recessed portion. A scuff band is received within the recessed portions so that at least a portion of the scuff band is outward of the common plane.

BACKGROUND OF THE INVENTION

This is a division of U.S. application Ser. No. 10/720,560, filed Nov.24, 2003, which is a continuation of U.S. application Ser. No.10/308,611, filed Dec. 2, 2002 (now U.S. Pat. No. 6,682,127), which is adivision of U.S. application Ser. No. 09/909,065, filed Jul. 19, 2001(now U.S. Pat. No. 6,497,451), the entire disclosure of each of whichare incorporated by reference herein.

A wide variety of trailers are known for carrying cargo. For example,van type trailers typically include a deck assembly supported by a sidewall structure, wheels and front legs. The deck assembly may includelongitudinal floor boards and transverse cross-members, such as I-beams,extending between opposing bottom rails. The deck transfers its load tothe bottom rails, wheels, and, depending upon whether or not the traileris coupled to a tractor or is free-standing, to a tractor fifth wheel orto retractable front legs on the trailer.

In a monocoque type trailer, individual interior side wall panel membersand an outer skin are joined together, often by a post, channel orzee-shaped structural member, and to a subframe to form aself-supporting body construction. The outer skin and inner panelmembers may carry some of the stresses between the posts, floor and roofof the trailer.

For example, it is known for the interior panels and the outer skin toattach to a plurality of vertical posts spaced apart along the trailerside wall. Referring to the cross-sectional view of a prior art verticalpost shown in FIG. 1, a vertical post 1 includes a longitudinal centralsection 2 and a pair of first longitudinal flanges 3 disposed on eitherside of central section 2 and recessed from central section 2 betweenthe central section and an outer skin 4. The outer skin is fastened to apair of second longitudinal flanges 5 by any suitable means, such asrivets (not shown). Side wall liner panels 6 are attached to the postsat first longitudinal flanges 3 by tapit pins 7.

It is known to include a scuff band along the interior surface of atrailer wall to prevent damage to the wall when cargo is loaded into orremoved from the trailer. If provided, the protective scuff bandgenerally protrudes into an otherwise useable storage area within thetrailer.

SUMMARY OF THE INVENTION

The present invention recognizes and addresses the foregoingconsiderations, and others, of prior art construction and methods.Accordingly, it is an object of the present invention to provide animproved trailer.

This and other objects are achieved by a trailer having a floor andfirst side wall that extends vertically upward from a side edge of thefloor. The side wall includes a plurality of elongated vertical posts.Each post defines a longitudinal interior surface with a first portiondisposed in a generally common plane and a second portion recessed fromthe plane. A scuff band is received within the recessed portions so thatan interior facing surface of the scuff band is generally coplanar withor inward of the side wall's interior surface.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate one or more embodiments of theinvention and, together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendeddrawings, in which:

FIG. 1 is a cross-sectional view of a prior art side wall post;

FIG. 2 is a partial perspective view of a trailer constructed inaccordance with an embodiment of the present invention;

FIG. 3 is a partial plan view of the interior of a side wall constructedin accordance with an embodiment of the present invention;

FIG. 4 is a partial plan view of the interior of a side wall constructedin accordance with an embodiment of the present invention;

FIG. 5 is a partial cross-sectional view of a trailer floor, bottomrail, top rail, and side wall with recessed scuff band constructed inaccordance with an embodiment of the present invention;

FIG. 6A is a perspective view of a bottom portion of a vertical sidewall post showing a recessed portion of the post constructed inaccordance with an embodiment of the present invention;

FIGS. 6B-6D show cross-sectional views of side wall posts in accordancewith embodiments of the present invention;

FIGS. 7A-7D show cross-sectional views of side wall posts in accordancewith embodiments of the present invention;

FIG. 8 is a partial cross-sectional view of a reinforcing channelpressed into a side panel as in FIGS. 7B and 7C;

FIG. 9 is a partial cut-away plan view of side wall as shown in FIG. 7B;and

FIG. 10 is a partial plan view of the interior of a side wallconstructed in accordance with an embodiment of the present invention.

Repeat use of reference characters in the present specification anddrawings is intended to represent same or analogous features or elementsof the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Reference will now be made in detail to presently preferred embodimentsof the invention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation ofthe invention, not limitation of the invention. In fact, it will beapparent to those skilled in the art that modifications and variationscan be made in the present invention without departing from the scope orspirit thereof. For instance, features illustrated or described as partof one embodiment may be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

FIG. 2 illustrates a trailer 8 having a floor 10, two side walls 12 anda roof 16. Each side wall 12 is identically constructed. Thus, while thepresent discussion generally refers to one side wall, it should beunderstood that such structure is included in each side wall. Roof 16 isattached to side walls 12 by top rails 18, and each side wall isconnected to floor 10 by a bottom rail 22 (one of which is shown in FIG.2). The trailer includes retractable legs 24, a forward end wall 26 anda rearward end frame 28. Once assembled, the roof, floor and side wallsform a trailer having a generally rectangular cross-section when viewedfrom the rear. The distance between inner surfaces of each side wall 12is generally greater than 90 inches, and the distance between outersurfaces of each side wall 12 is generally less than 110 inches.

A pair of doors 30 at the trailer's rearward end are pivotally connectedto rear end frame 28. A plurality of wheels, 34 support the trailer'srearward end and facilitate movement of the trailer when coupled to atractor (not shown).

Referring also to FIGS. 3 and 9, side wall 12 includes a plurality ofvertical posts 36, a plurality of interior side wall liner panels 38 andone or more scuff bands 40. The liner panels interconnect the posts, andthe scuff band is received within a recessed portion 80 of a bottomportion of posts 36. Each post includes a longitudinal front face 78through which is defined a series of apertures 42 (not shown in FIG. 9)for receipt of cargo straps and the like to secure the trailer contents.

Panels 38 are fastened at 46 to posts 36 by screws, rivets, tapit pins,or any other suitable method. The panels are constructed of plywood orother suitable materials, for example steel. Referring specifically toFIGS. 7B, 7C, 8 and 9, corrugated metal panels include a plurality ofrecessed channels 48 that give the panels added structural strength andstiffness.

Referring again to FIG. 3, posts 36 are fastened to top rail 18 bysuitable means such as rivets, screws or the like. Thus, the panels aresecured to the top rail though their connection to the posts. An outerskin 21 (FIG. 2) is fastened to the trailer's top and bottom rails asdiscussed in more detail below. Referring also to FIG. 5, the portion ofthe top rail to which the posts are fastened extends behind liner panels38 as the panels are illustrated in FIG. 3. Thus, it should beunderstood that FIG. 3 illustrates only an upper portion of top rail 18.

In another embodiment illustrated in FIG. 4, side wall 12 includeshorizontally oriented interior side wall liner panels 58 fastened tohorizontal logistic tracks 60 by a suitable fastening means at 62. Toprail 18 may be separately fastened to the horizontal panels. Logistictracks 60 are fastened to vertical posts 36 (in phantom) disposedintermittently along the trailer side wall between liner panels 58 andthe outer skin. Panels 58, particularly the uppermost and lowermostpanels, may also be fastened to vertical posts 36. Scuff band 40, whichis fastened to vertical posts 36, may be corrugated or otherwiseprofiled or flat, but its inner face is generally coplanar with aninterior surface of panels 58 and an interior face 78 of horizontaltracks 60.

Still referring to FIG. 4, vertical posts 36 are fastened to outer skin21 (FIGS. 7A-7D) and to the top and bottom rails. Liner panels 58 may beof a wooden, polymer, composite or metallic construction. They may beattached to the tracks in any suitable manner, for example tolongitudinal flanges recessed from, and on either side of, front face78. Alternatively, tracks 60 may include multiple recessed flanges asdescribed below with reference to FIGS. 7A-7D, particularly where theliner panels are corrugated.

As illustrated in FIGS. 2-5, scuff band 40 is of a generally corrugatedmetal construction. However, the scuff band may be constructed of anysuitable material, for example wood, with or without a protective metalplate attached, or a non-corrugated metal. In preferred embodiments,scuff band 40 is formed from three-quarter inch plywood or sixteen gaugegalvanized steel corrugated to a one-quarter inch depth.

Referring again to FIG. 2, exterior skin 21 is connected to top rail 18,bottom rail 22, end wall 26 and end frame 28. In one embodiment, outerskin 21 is constructed of “nominal” 050 aluminum, having a thickness ofapproximately 0.047 inches, and is fastened to vertical posts 36 byrivets or other suitable means. Vertical posts 36 are riveted to the topand bottom rails of both side frames.

As shown in FIG. 5, trailer floor 10 includes two longitudinallyoriented zee-shaped members 70 (one of which is shown in FIG. 5) betweenbottom rail 22 and longitudinally oriented wooden floor planks 74. Thezee-shaped members and the floor planks sit on a plurality of transverseI-beams 72. Each I-beam 72 includes an end plate 73 welded to each end,and end plates 73 are fastened to a bottom portion of bottom rail 22.Wooden planks 74 may be held between opposing zee-shaped members 70 byfriction, or the planks may be bolted or otherwise fastened to I-beams72 and/or zee-shaped members 70. Zee-shaped members 70 may beintermittently attached to bottom rails 22, I-beams 72, and/or planks74. Outer skin 21 is riveted to vertical posts 36, and posts 36 areriveted to bottom rail 22 and top rail 18, as shown at 76.

Referring now to FIG. 6A, an exemplary post 36 includes a recessed lowerportion 80 defined in front face 78. Stepped-down pairs of longitudinalflanges 88 and 82 extend out from opposite sides of front face 78 toouter edges 84 and 86 and are parallel to each other and to front face78. Flanges 88 are recessed approximately one-quarter of an inch fromfront post face 78 and define lateral edges 87 at the transition toflanges 82. Flanges 88 and 82 are generally parallel to front face 78.That is, they may deviate slightly from true parallel and/or may bediscontinuous along their lengths, yet they are still able to receiveand support liner panels (e.g. as shown in a three-flange embodiment inFIG. 9) and/or compress in an accordion fashion as described herein andgenerally encompassed by the present invention, as should be understoodby those skilled in the art.

Referring also to FIGS. 6B and 6D, each flange 82 extends continuouslyalong the length of post 36. In contrast, flanges 88 are parallel tosurface 78 and flanges 82 only above a transition section 90. Belowtransition section 90, flanges 88 bend outward away from the planedefined by front post face 78, allowing portion 80 to recess to aposition approximately coplanar with the inward surface of flanges 88above the transition section. A distance D1 (FIG. 6D) between anexterior surface of the outer flanges and an interior facing surface ofrecessed portion 80 is approximately 0.37 inches in one embodiment.

Because flanges 82 maintain their positions across transition section90, the movement of front face 78 inward to form recessed portion 80pivots flanges 88 at edges 87, thereby forming a pair of angled surfaces92. Edges 87 and post edges 84/86 remain straight and parallel to eachother, and the indention of recessed portion 80 does not expand thewidth of post 36. Outer skin 21 may be attached to the post along thepost's entire length, and the post may be attached both to the trailer'stop and bottom rails, at the rear face of flanges 82 at 83.

Prior to the indention of recessed portion 80, the post's cross-sectionis consistent along its entire length, as shown in FIG. 6B. To form therecessed portion, and referring to FIG. 6C, the lower portion of post 36is disposed between an upper die piece 85 and a lower die piece 93. Diepiece 85 may be forced toward piece 93 as indicated at 94, or die piece93 may be forced toward die piece 85 as indicated at 96, therebydeforming the post's lower end as shown in FIG. 6D. It should beunderstood that the post shapes may vary, and differing dieconfigurations may therefore be used as appropriate. Preferably,however, the post's stamped lower end defines: a flat front outersurface and an accordion flange structure between the front face and thepost's side edges. The die maintains the position of the side edges sothat the accordion collapses as the die pushes in the selected portionof the front face. Accordingly, the post maintains a constant widthwhile the recessed portion provides a surface for receipt of the scuffband.

When received by the recessed portion, at least a portion of the scuffband is disposed outward of the post front face. Referring to FIGS. 5and 9, the scuff band may be almost entirely outward of the trailer'sinterior area so that scuff band's front surface is substantiallyparallel to post front face 78 above transition section 90. Returning toFIGS. 6A-6D, flanges 88 above transition section 90 may receive innerliner panels 38 (FIG. 2) against an abutting surface 102 so that theliner panels, post face 78 and the scuff band are substantiallycoplanar. That is, while there may be slight deviations in the surface,as should be understood in the art, the surface is coplanar from thestandpoint of maximizing cargo space in the trailer.

It should be understood, however, that the scuff band may notnecessarily be substantially coplanar with the trailer's inner side wallsurface. For example,.post portion 80 may be recessed by one-quarterinch but receive a half-inch thick scuff band. In this arrangement, onlyhalf the scuff band is outward of the inner side wall. Thus, the scuffband front face is inward of the inner side wall, but the recessed postnevertheless saves a quarter inch at each wall.

Furthermore, the scuff band may be disposed at any suitable position inthe wall. Referring to FIG. 10, for example, scuff bands are disposed atthe top and bottom of the wall, and the posts define recessed portions(not shown) at both ends. Moreover, the posts may be recessed whereverit is desired to place scuff bands, and the posts may be recessed at oneor more intermediate points to receive one or more scuff bands.

The horizontal logistic tracks illustrated in FIG. 4 receive the linerpanels so that the panels are generally coplanar with the front faces ofthe tracks. The scuff band may be disposed below the liner panels withinrecessed portions in the vertical posts so that the panels, logistictracks and scuff band form a substantially uniform surface.

It should be understood that the present invention encompasses variouspost configurations. Referring now to FIG. 7A, for example, post 36A isgenerally hat shaped and includes a front face 78 and three stepped-downlongitudinal flanges on either side of the front face. A pair of flanges54A extend outward form the front face, followed by flanges 88A and 82A.A plywood interior liner panel 38 is fastened to post 36A at first innerflanges 88A by tapit pins 66 so that an interior facing surface of panel38 is substantially coplanar with front face 78. The heads of tapit pins66 may extend out from this surface but could also be countersunk in theliner panels so that the heads are at or below the panel surfaces. Outerskin 21 is attached to rear faces of flanges 82A at 99.

Referring now to FIG. 7B (and FIG. 9), post 36B includes three flanges82B, 88B, and 54B in a configuration similar to post 36A, but interiorside wall liner panels 38B are of a metallic construction. Each metallicinner side wall liner panel defines a main body portion 39, which iscorrugated by a series of parallel recesses 48 (FIG. 8), and flanges 52that rest on flanges 54B. Screws 56 fasten flanges 52 to the flanges. Inone preferred embodiment, as shown in FIG. 8, recessed channels 48 forma trapezoidal shaped depression in panel main body portion 39 andinclude opposing sides defining an angle of approximately 45 degreeswith respect to a plane defined by an interior facing surface of thepanel.

Flanges 52 in a preferred embodiment extend approximately one half inchfrom liner panel main body portion 39 to the panel's side edge. Linerflanges 52 may be formed by folding back a portion of the liner panel sothat the thickness of panel flanges 52 is double the thickness of themain panel body. The width of panel flanges 52 may vary in accordancewith the particular post design.

Referring to FIG. 7C, post 36C includes three stepped-down planarflanges behind post front face 78. A pair of outer flanges 110 extendinward from edges 84C and 86C. A pair of first inner flanges 112 aredefined between outer flanges 110 and a pair of second inner flanges114. Metallic interior side wall liner panels 38 are screwed to post 36Cat second inner flanges 114. An adhesive sealant may be applied betweenouter flanges 110 and a rear face 108 of recessed channels 48. Referringalso to FIG. 7B, an adhesive sealant could also be used between channelrear face 108 and first inner flanges 88B.

In the embodiments illustrated in FIGS. 7A-7B, the post's rearwardmostplanar surface is defined on an exterior surface of outer flanges 82A-Band is adjacent to post edges 84 and 86. In these embodiments, outerskin 21 (shown in phantom on FIGS. 7A-7D) attaches to outer flanges82A-B at 99. In the embodiments illustrated in FIGS. 7C and 7D, however,outer skin 21 fastens to an exterior surface of first inner flanges 112.Thus, it should be understood that the present invention encompasses anysuitable lateral position of the flanges.

Referring to FIG. 7D, post 36D is configured similarly to post 36C, butit receives a plywood interior side wall liner panel 38 fastened toouter flanges 110 by tapit pins 66. Plywood panels 38 are approximatelyone quarter of an inch in thickness.

While one or more preferred embodiments of the invention have beendescribed above, it should be understood that any and all equivalentrealizations of the present invention are included within the scope andspirit thereof. The embodiments depicted are presented by way of exampleonly and are not intended as limitations upon the present invention.Thus, it should be understood by those of ordinary skill in this artthat the present invention is not limited to these embodiments sincemodifications can be made. Therefore it is contemplated that any and allsuch embodiments are included in the present invention as may fallwithin the literal and equivalent scope of the appended claims.

1. A cargo trailer for use with a motorized vehicle, said trailercomprising: a wheel assembly; a floor supported by said wheel assembly;and two side walls extending upward from respective longitudinal sidesof said floor, at least of one of said side walls including an outersurface, an inner surface, a plurality of elongated posts disposedbetween said outer surface and said inner surface, and a plurality ofinterior side wall liner panels, wherein each said liner panel isdisposed between respective said posts and partially defines said innersurface and wherein each said liner panel has a corrugated main portionand flanges extending from said corrugated main portion, wherein eachsaid post includes a longitudinal first portion that partially definessaid inner surface, a pair of first longitudinal flanges generallyparallel to and disposed on opposite sides of said first portion andrecessed from said first portion between said inner surface and saidouter surface, and a pair of second longitudinal flanges generallyparallel to and disposed on opposite sides of said first portion andrecessed from said first longitudinal flanges between said firstlongitudinal flanges and said outer surface, and wherein said linerpanel flanges of each said liner panel are attached to said firstlongitudinal flanges of adjacent said posts so that said corrugated mainportion engages said second longitudinal flanges of said adjacent posts.2. The trailer as in claim 1, including a pair of third longitudinalflanges generally parallel to and disposed on opposite sides of saidfirst portion and recessed from said second longitudinal flanges betweensaid second longitudinal flanges and said outer surface, wherein saidouter surface includes an outer skin, and wherein said outer skin isfastened to each said post at said pair of second longitudinal flanges3. The trailer as in claim 2, wherein each said third longitudinalflange is attached to and disposed laterally between respective saidfirst and second longitudinal flanges.
 4. The trailer as in claim 2,wherein each said second longitudinal flange is attached to and disposedlaterally between respective said first and second longitudinal flanges.5. The trailer as in claim 1, wherein said plurality of elongated postsare horizontally oriented and parallel to said floor.
 6. The trailer asin claim 5, including a plurality of elongated vertical posts disposedbetween said outer surface and said horizontal posts, said horizontalposts being attached to said vertical posts.
 7. The trailer as in claim1, wherein said plurality of elongated posts are vertically oriented. 8.A cargo trailer for use with a motorized vehicle, said trailercomprising: a wheel assembly; a floor supported by said wheel assembly;and two side walls extending upward from respective longitudinal sidesof said floor, at least one of said shade walls including an outersurface, an inner surface, a plurality of elongated posts disposedbetween said outer surface and said inner surface, a plurality ofinterior side wall liner panels, wherein each said liner panel isdisposed between respective said posts and partially defines said innersurface, wherein each said post includes a longitudinal first portionthat partially defines said inner surface, a pair of first longitudinalflanges generally parallel to and disposed on opposite sides of saidfirst portion and recessed from said first portion between said innersurface and said outer surface, a pair of second longitudinal flangesgenerally parallel to and disposed on opposite sides of said firstportion and recessed from said first longitudinal flanges between saidfirst longitudinal flanges and said outer surface, and a pair of thirdlongitudinal flanges generally parallel to and disposed on oppositesides of said first portion and recessed from said second longitudinalflanges between said second longitudinal flanges and said outer surface,and wherein each said liner panel is attached to respective said firstflanges, and/or respective said second flanges, of adjacent said posts.9. The trailer as in claim 8, wherein said posts are verticallyoriented.
 10. The trailer as in claim 8, wherein said outer surfaceincludes an outer skin, and wherein said outer skin is fastened to eachsaid post at said pair of third longitudinal flanges.
 11. The trailer asin claim 8, wherein each said liner panel is attached to respective saidsecond flanges of adjacent said posts.
 12. In construction of a cargotrailer having a wheel assembly, a floor supported by the wheelassembly, and two side walls extending upward from respectivelongitudinal sides of the floor, wherein at least one of the side wallsincludes an outer surface, an inner surface and at least one verticalpost disposed between and supporting the inner surface, a method offorming the vertical post, said method comprising the steps of:providing an elongated metal post having a generally planar longitudinalcentral surface, a pair of stepped accordion flanges respectivelydisposed on opposite sides of said central surface, and a pair ofelongated side edges respectively defined on opposite sides of saidpost; securing said elongated side edges against lateral deformation;and stamping a predetermined area of said central surface at an end ofsaid post so that said predetermined area is recessed with respect to aremaining portion of said central surface and so that said accordionflanges compress between said central surface and said elongated sideedges.
 13. The method of claim 12, wherein said stamping step includesproviding a first die piece and a second die piece, and wherein eachsaid die piece defines opposing accordion shaped surfaces.
 14. Themethod of claim 12, wherein said recessed stamped area is defined in agenerally common plane with a pair of longitudinal flanges within saidstepped accordion flanges offset from said stamped area and parallel tosaid central surface.
 15. The method of claim 14, wherein saidlongitudinal flanges are defined adjacent to said generally planarlongitudinal central surface.